Waste Powder Paint User Group

Notes on Initial MeetingApril 19, 2011

Objectives for the event

1. Gage the level of interest from the group for continued meetings/activities

2. Identify the focus for a second meeting3. Decide how future meeting coordination will

be accomplished

History of this event

• The problem was brought to our attention by Mr. Bill Gurn of Haworth at a May 5-6 conference of the Green Manufacturing Initiative

• Further investigation verified that this was a significant problem – outlets for spent powder were limited

• Mr. Gurn suggested that WMU coordinate an opportunity for a meeting of users to discuss the problem and share experiences

The Problem

• Lean Manufacturing (Producing to Customer Demand) has confounded one of the benefits of powder paint – the ability to reclaim and reapply

• Frequent color changes lead to:– Mixed Colors– Mixed Materials (powder technologies)

• Recycling challenges:– Degradation of the polymer if re-processed– High volume of waste ≠ capacity of outlets

Some Current Outlets

• Small scale research projects, i.e. GMI Composites Inc. (using waste paint in compounding agents for compression molding)

• Innotec Inviromass (molded counterweights) and other green products

• Polyflow process (pyrolysis)• Plastic Pallet Manufacturing - PF

Proposed Graduate Research at WMU

• The concept will investigate the use of waste powder paint as a filler for injection molding resins.– Primarily as a filler for

thermoplastic resins.– A recycled resin that is

useable in standard injection molding equipment.• Blended with common

use resins.• Progression of Research

– Spring 2011-Winter 2011

Evaluation of the types of powder used at facilities– Review whether powders are polyesters, epoxy-

based, TGIC, etc.– Are the waste powder streams mixes of different

types of resins? How does this complicate the process?

– When? Now• Quality

– What are the nominal particle sizes? Does particle size vary by resin type?

– How do metalized powder paints affect the quality?– What supply chain quality measures would be

necessary?• Supply Chain

– Investigating cost factors of transportation of materials.

– Are networks established currently for such wastes?

Powder Paint Blending Research

Powder Paint Blending Research

• Development of two phase blends of virgin thermoplastics with powder paint fillers.– DSC analysis to determine heating curves.– Compatibilizers may be needed or other

chemical derivatives in the creation of the composite blend. The use of compatibilizers is common for blending dissimilar polymers together. The purpose of these chemicals is to reduce the interfacial energy between the polymers and thereby improve the adhesive properties of the polymers (17).

– Study of the rhealogy of the new resin composites.

– Determination of base virgin resins.– When? Summer 2011

• Processing of Test Bars– Molding of test composite parts.

• Observing process characteristics of the composite blends.– Process pilot size runs with industry products.

• Determining a proper low-temperature base resin.– Developing working process profiles.

• Conduct analysis on various material properties of the test bar and evaluate compared to the virgin resin.– Tensile Strength– Elongation at Break– UV & Weatherability

• Last part of research would be the scalability of this project and economics.

• When? Summer & Fall 2011

Blending and Chemical Processing Processing of Test Bars & Mechanical Analysis

Survey Results

User's Group Total Surveys Submitted: 6

Total number of facilities that use powder paint: 11

Total lbs purchased per year: 3,927,957 (estimated)

Average cost per lb: $3.47 (missing data)

Total disposal cost: $12,701

Average disposal cost: $2,117

Total waste in lbs per year: 1,454,173

Average facility transfer efficiency: 63%

Average waste powder recycled: 18%

Average waste going to landfill: 68.4%

Average amount being reclaimed: 11.2%

Calculated based on group transfer efficiency and waste data

Average of 5 respondentsRange $34 - $5,538

Annual Purchase Cost $5,045,980.31

Range 50-70% (5 resp.)

Range 0 – 50%

Range 0 – 100%

Range 0 – 30%

Breakdown on Powder Technologies

68%

25%

4% 2%

0%

Epoxy-Polyester Hybrid:Polyester Triglycidyl Isocya-nurate (TGIC)Urethane-PolyestersPolyesters-HyrdoxlEpoxy Based

Open Discussion

• What outlets have you investigated?• What success have you had?• What outlets would you like investigated?• Would you be willing to suggest and sponsor

university research?

The group openly shared information on previous and current activities focused on finding outlets for this material.

Levels of Engagement

Meeting 2 Planning

• Others to Invite:– Suppliers– Solutions Providers– Polymer Experts from Industry– Others from academe

• Topics for discussion:– Presentations/Proposals from solutions providers– Expert overview of the reasons for recycling

limitations (Polymer chemists or paint suppliers)

Future Meeting Coordination

• Location: move between large company members (Haworth, Steelcase, Herman Miller)

• Coordination/management – MMTC is willing to commit to this provided that their costs are covered– Suggest a tiered “donation” structure with large

users covering more of the cost